Method for producing a component, and device

ABSTRACT

A method for producing a component for a turbomachine, having the additive build-up of the component by an additive production method from a base material for the component and the introduction of material fibers into a construction for the component during the additive build-up in such a way that the material fibers are oriented in a circumferential direction of the component around a component axis and in such a way that a fiber composite material is produced, including the material fibers and a base material that is solidified by the additive build-up. A corresponding component is produced by the method and a corresponding device is used for producing the component.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is the US National Stage of International ApplicationNo. PCT/EP2017/051645 filed Jan. 26, 2017, and claims the benefitthereof. The International Application claims the benefit of GermanApplication No. DE 102016201838.8 filed Feb. 8, 2016. All of theapplications are incorporated by reference herein in their entirety.

FIELD OF INVENTION

The present invention relates to a method for producing a component parta component for a turbomachine. The present invention furthermorecomprises the component and a device for producing the component.

The component can be a turbine disk. The term “turbine disk” is in thepresent case to be understood as being synonymous to turbine ring orrotor disk. The component can also be a rotor part or a part of acompressor, or compressor of a gas turbine. The component is alsoadvantageously an additively or generatively produced or built-upcomponent.

BACKGROUND OF INVENTION

Known layered, additive or generative production methods are especiallyselective laser melting (SLM), selective laser sintering (SLS) andelectron beam melting (EBM). Additive production methods are for theproduction of three-dimensional individually formed components by meansof their iterative stacking or joining together of layers, layerelements or volumetric elements, for example from of a powder bed.Typical thicknesses of the individual layers lie between 20 μm and 60μm.

A large number of different materials, for example ceramic materialsand/or metallic materials, which can exist both in powder form orgranulate form, but also in the form of fluids, e.g. as suspensions, areavailable as source materials. In generative production methods, thethree-dimensional object is formed by a multiplicity of individualmaterial layers which are deposited one after the other on a lowerablebuild-up platform and then individually subjected to a locally selectivesolidification process.

A method for selective laser melting is known from EP 1 355 760 B1, forexample.

Turbine parts are exposed to particularly high thermal and/or mechanicalloads during their application or operation. In this case, thermal andmechanical loads of a gas turbine or of its rotor parts during operationcan be interrelated, for example in the form of thermo-mechanicalstresses.

In addition to the development of ever temperature-resistant materials,there is therefore also a demand for materials, for example compositematerials, which have improved mechanical properties. Whereas inthermally highly loaded regions of a turbine, for example attemperatures of above 600° C., a high degree of strength of thematerials is required, in inner regions or inner parts of the turbine,of the compressor or of a corresponding rotor disk a high level ofductility is especially required.

SUMMARY OF INVENTION

It is therefore an object of the present invention to specify meanswhich improve the mechanical properties especially of rotatable turbineparts, and/or to make the operation of the turbine more reliable and/ormore efficient.

This object is achieved by means of the subject matter of theindependent claims. Advantageous embodiments are the subject matter ofthe dependent claims.

One aspect of the present invention relates to a method for producing acomponent for a turbomachine, for example for a gas turbine, such as arotor disk for a gas turbine, comprising the additive build up of thecomponent by means of an additive production method. The component forthe additive build up is especially built up from a matrix or basematerial, advantageously from a powder-form base material, for thecomponent. The stated material can be a nickel-based, a cobalt-based oran iron-based material.

The method also comprises the introduction of material fibers into aconstruction for the component during the additive build up in such away that the material fibers are oriented along, or basically along, acircumferential direction of the component, advantageously around acomponent axis, and in such a way that a fiber composite material iscreated, the fiber composite material expediently comprising thematerial fibers and a base material which is solidified as a result ofthe additive build up, wherein the material fibers also comprise ceramicmaterial, especially consisting of aluminum oxide, mullite, SiBCN, SiCNor SiC.

In one embodiment, the component is a rotatable part, and especiallyrotating during operation of the turbomachine.

In one embodiment, the component is a rotationally symmetrical part, orbasically rotationally symmetrical part, of the turbomachine, or for theturbomachine.

The circumferential direction advantageously refers in the present casea direction which corresponds to a rotation direction or direction ofrevolution of the component during its operation, advantageously duringits application in the turbomachine. The circumferential direction canbe a tangential direction.

The circumferential direction can especially describe a circumference ofthe component axis or at least partially comprise a geometricdirectional component along the circumference of the component.

The term “construction” can describe the component itself. An onlypartially (additively) produced part of the component can especially bemeant by this, for example at a point in time during an additiveproduction and in a corresponding facility or device for the additiveproduction.

The material fibers can be principally or predominantly oriented in, oralong, the circumferential direction. For example, the material fibers,apart from necessary twists or production-induced deviations from thecircumferential direction, can be oriented along this direction and/orintroduced into the construction. However, the material fibers do notnecessarily have to be oriented concentrically to the component or toother fibers.

By means of the described method, in a particularly advantageous manner,a fiber composite material or a fiber composite substance can at leastpartially be additively produced or built up, or the correspondingproduction can be implemented in an additive production process. Theknown advantages of fiber composite materials can especially be utilizedaccording to the described method for the production and the applicationespecially as a rotor part of a gas turbine, for example of a compressordisk. For example, creep resistance or the resistance to tensile load ofthe component perpendicularly to the fiber direction can be improved bythe use of fiber composite materials.

At the same time, the advantages of additive production technology canalso be utilized synergistically in this case.

In one embodiment, the additive production method is a powder bed-basedadditive production method.

In one embodiment, the additive production method is a beam meltingmethod.

In one embodiment, the additive production method is selective lasermelting, selective laser sintering, electron beam melting or laserdeposition welding.

In one embodiment, the material fibers are introduced into theconstruction of the component by means of a robot-controlled orrobot-guided device.

In one embodiment, the material fibers, for example as seen along abuild-up direction of the component, are arranged or introduced only inone, especially central, radial region of the component andadvantageously not across the entire radial extent. This region canespecially be a radial “waist region” of the component which duringoperation of the component is exposed to particularly high mechanicalloads.

In one embodiment, the material fibers are interwoven during theadditive build up.

In one embodiment, the base material is arranged at least partiallybetween the material fibers.

In one embodiment, the material fibers are provided with a coatingbefore introduction.

A further aspect of the present invention relates to a component for aturbomachine, wherein the component is produced, or can be produced, bymeans of the described method.

In one embodiment, the component is a rotor part of a turbomachine, forexample of a gas turbine.

In one embodiment, the component is a turbine disk which is designed forthe mounting of a rotatable part of a turbomachine during operation. Therotatable part can be for example a compressor blade.

A further aspect of the present invention relates to a turbine disk fora turbomachine comprising, for example, a radial region, especially acentral or middle radial region, and a fiber composite material, asdescribed above. The fiber composite material also comprises thematerial fibers and a matrix material, wherein the material fibers areoriented along a circumferential direction of the turbine disk andwherein the material fibers also comprise ceramic material, especiallyconsisting of aluminum oxide, mullite, SiBCN, SiCN or SiC.

The matrix material of the fiber composite material advantageouslyrefers to a base material which is solidified during, or as a result of,the additive production.

In one embodiment, the material fibers comprise one or more of thefollowing materials: carbon, boron, basalt and/or ceramic material,especially consisting of aluminum oxide, mullite, SiBCN, SiCN and SiC.

In one embodiment, the fiber composite material and/or the materialfibers comprise carbon (C), silicon carbide (SiC) and/or aluminum oxide,for example Al₂O₃. The fiber composite material and/or the materialfibers can comprise the stated materials for example as the principleconstituent.

In one embodiment, the matrix material and/or base material comprisescarbon, silicon carbide and/or aluminum oxide. The matrix materialand/or base material can comprise the stated materials for example asthe principle constituent.

In one embodiment, the coating of the material fibers comprisesespecially carbon and/or boron nitride (BN).

A further aspect of the present invention relates to a device forproducing a component for a turbomachine, wherein the device is designedfor additively building up the component from for example a powder-formbase material. The device also comprises an appliance for introducingmaterial fibers into the construction for the component in such a waythat the material fibers are oriented along the circumferentialdirection of the component and in such a way that the fiber compositematerial is produced. The fiber composite material expedientlycomprises—as described above—the material fibers and the solidified basematerial.

Embodiments, features and/or advantages which in the present case relateto the method can also relate to the device and/or to the component, andvice versa.

BRIEF DESCRIPTION OF THE DRAWINGS

Further details of the invention are described below with reference tothe drawing.

FIG. 1 schematically shows a top view of a device for the additiveproduction of a component for a turbomachine.

FIG. 2 schematically shows a sectional or side view of a device for theadditive production of a component for a turbomachine.

FIG. 3 schematically shows a cross section through a turbine disk.

DETAILED DESCRIPTION OF INVENTION

FIG. 1 schematically shows a top view of a device 10. The device 10 is adevice for the additive production of a component 1. The device 1 isadvantageously a device for the layered build up of a component from apowder bed, for example a device for selective laser melting, as shownin FIG. 1. Alternatively, the device 10 can be a device for selectivelaser sintering and/or for electron beam melting.

A method according to the invention for producing the component 1 isdescribed based on the device 10 and with reference to FIGS. 1 and 2.

The component 1 is especially a rotor part of a turbomachine, such as agas turbine. The component 1 especially refers to a turbine disk, aturbine ring or a rotor disk of a compressor of the turbine.

The device 10 has a construction platform 8 (cf. FIG. 2) on which isarranged a advantageously powder-form source or base material 2 for thecomponent 1. The base material 2 can for example be a nickel-based, acobalt-based or an iron-based material.

Shown on the construction platform 8 is a build up of the component. Inthis case, it can be a partially built-up component and/or can be thecomponent during its additive production. The component 1 is expedientlyof rotationally symmetrical design, or in the main of rotationallysymmetrical design. As the rotor part of a turbomachine or of acompressor thereof, the component is also advantageously rotatable, e.g.rotatable relative to stator components of the turbomachine. Thecomponent advantageously rotates during the designated operation of theturbine.

For the additive build up, the device 10 has a solidification device 9.In this case, it can be a solidification device of the prior art. Thesolidification device 9 is advantageously a computer-controlled orcomputer-controllable unit which for solidifying the base material 2 isequipped with a laser or an electron beam device (not explicitlyidentified). For the solidification, the base material 2 isadvantageously first of all melted and then solidified.

For applying the base material 2, the device 10 has a coating ordeposition device 7. In this case, it can be a doctor blade with whichthe advantageously powder-form base material 2 can be distributed ordeposited on the build platform 8. This can be carried out for examplealong a coating direction B.

As an element according to the invention, the device 10 is also anappliance 5. The appliance 5 is designed for introducing material fibers3 into the build up for the component 1, specifically in such a way thatthe material fibers 3 are oriented at least in the main along acircumferential direction or rotation direction, identified by thedesignation A, of the component 1 during operation.

The dashed (concentric) circles, which are shown inside the component 1in FIG. 1, advantageously indicate a region in which the material fibers3 are arranged and/or introduced. The material fibers are also shownonly in sections. With reference to the depicted sections, it is to beseen that the direction of orientation or alignment corresponds to thecircumferential direction A.

The appliance 5 is advantageously also designed in such a way that theintroduction of the material fibers 3 creates a fiber composite material4 comprising the material fibers 3 and a solidified base material ormatrix material (for the sake of simplicity this is identified by thedesignation 2 in the same way as the base material. The fiber compositematerial 4 can be formed by the material fibers 3 and the matrixmaterial.

The appliance 5 is advantageously robot-controlled. As shown in FIG. 1,the appliance 5 can comprise a robot arm which is shown onlyschematically in the illustration. This robot arm is pivotable forexample across the production area of the construction platform 8 or thecomponent 1 in such a way that the material fibers 3 can be “built into”the component, as described above, during the additive build up of thebase material. Said robot arm can also be for example of telescopicallyextendable design.

Within the scope of the present method, the material fibers 3—with theaid of the appliance 5—are introduced into the constructionadvantageously during the additive build up or the additive productionof the component 1 so that the fiber composite material 4 is created andthe fibers are oriented in the same way as described above. One fiberlayer (cf. FIG. 1) can be introduced per additively built-up and/orsolidified layer of base material. This takes place advantageouslybefore the base material 2 is deposited or distributed by means of thecoating device 7 so that a corresponding layer can be formed or producedfor the fiber composite material. The base material 2 is advantageouslydeposited in such a way and/or the material fibers are introduced insuch a way that base material 2 is at least partially arranged betweenthe material fibers 3.

The material fibers 3 can especially also be interwoven.

It is also provided within the scope of the described method that thematerial fibers, for example before introduction into the constructionby means of the appliance 5, are provided or coated with a coating (notexplicitly identified). The coating can be a sliding or lubricantcoating, especially in order to enable a sliding movement of thematerial fibers 3 relative to the matrix material 2, which movement inturn has an effect upon the specific mechanical properties of the fibercomposite material 4.

FIG. 2 shows a schematic side view of a device 10. A build-up directionis identified by the designation C. As an alternative to the embodimentof the device of FIG. 1, the device 10—as shown in FIG. 2—can forexample also be a device for laser deposition welding, especially laserpowder deposition welding. Accordingly, the solidification device 9 inthis case advantageously comprises both a laser (not explicitlyidentified) for solidification of the base material 2 and a powdernozzle (not explicitly identified) by means of which the base material 2is made available.

FIG. 3 shows, in a simplified cross section, a finished component 1. Thecomponent 1—in comparison to the remaining sections—has a narrowed orwaisted central, or inner radial region 6. In this region, particularlyhigh mechanical loads can occur during operation of the component 1. Anupper, not identified, widening region of the turbine disk 1 isespecially provided both in order to keep turbine blades in place, forexample during operation of a gas turbine, and to make the turbineblades exchangeable, advantageously by axial sliding into or out of theformed cavities.

The central region 6 comprises the described fiber composite material 4.The central region 6 can consist of the fiber composite material 4. Inparticular, the material fibers 3 are shown in circular form in theregion 6 in the cross-sectional view of FIG. 4. The fiber compositematerial 4 and/or the component which is provided therewith—incomparison to a turbine disk of the prior art—especially has improvedmechanical properties, especially a higher fracture elongation orfracture-elongation loadability, e.g. by up to one percent. By the sametoken, the component 1 according to the invention, which is produced bythe described method, advantageously has a significantly increased crackresistance, an improved thermal shock resistance, and for exampleimproved thermo-mechanical properties.

Furthermore, an extensibility or extension loadability of the component1 relative to a conventional rotor part of a turbine can be increased by2%.

The fiber composite material 4—due to the specification of the fiberdirections—can have anisotropic and therefore especially mechanicalproperties.

The component 1 can especially be a rotor disk of a compressor or of acompressor stage of a gas turbine (advantageously upstream of thecombustion chamber of the turbine as seen in the flow direction). Thecomponent 1 can especially be a compressor rotor disk of the materialgrade “26NiCrMoV 14-5” or “Cost-E (X 1 2CrMoWVNbN 10-1-1”.

The described material fibers 3 can also comprise one or more of thefollowing materials: carbon, boron, basalt and/or ceramic material,especially aluminum oxide, for example Al₂O₃, mullite, SiBCN, SiCN andSiC.

By the description based on the exemplary embodiments, the invention isnot limited to these but covers each new feature and each combination offeatures. This especially contains each combination of features in thepatent claims, even if this feature or this combination itself is notexplicitly disclosed in the patent claims or exemplary embodiments.

1. A method for producing a component for a turbomachine, the methodcomprising: additive build up of the component by means of an additiveproduction method from a base material for the component andintroduction of material fibers into a construction for the componentduring the additive build up in such a way that the material fibers areoriented along a circumferential axis of the component around acomponent axis and in such a way that a fiber composite material iscreated, the fiber composite material comprising the material fibers anda base material which is solidified as a result of the additive buildup, wherein the material fibers comprise ceramic material.
 2. The methodas claimed in claim 1, wherein the material fibers are introduced bymeans of a robot-controlled appliance.
 3. The method as claimed in claim1, wherein the material fibers are introduced only in a central regionof the component, as seen along a build-up direction of the component.4. The method as claimed in claim 1, wherein the additive productionmethod is selective laser melting, selective laser sintering, electronbeam melting or laser deposition welding.
 5. The method as claimed inclaim 1, wherein the base material is arranged at least partiallybetween the material fibers.
 6. The method as claimed in claim 1,wherein the material fibers are provided with a coating beforeintroduction.
 7. A component for a turbomachine, wherein the componentis produced, by means of the method according to claim 1, wherein thecomponent is a rotor part of a turbomachine, or of a gas turbine.
 8. Thecomponent as claimed in claim 7, wherein the component is a turbine diskfor the mounting of a rotating part of a turbomachine, or a compressorblade, during operation.
 9. A turbine disk for a turbomachine,comprising: a fiber composite material comprising material fibers whichcomprise ceramic material, wherein the material fibers are orientedalong a circumferential direction or the turbine disk around a rotationaxis thereof during operation.
 10. The turbine disk as claimed in claim9, wherein the material fibers comprise one or more of the followingmaterials: carbon, boron and/or basalt.
 11. A device for producing acomponent for a turbomachine, wherein the device is designed foradditively building up the component from a base material, the devicecomprising: an appliance which is designed for introducing materialfibers into a construction for the component in such a way that thematerial fibers are oriented along a circumferential direction of thecomponent around a component axis and in such a way that a fibercomposite material is created, which fiber composite material comprisesthe material fiber and a solidified base material.
 12. The method asclaimed in claim 1, wherein the material fibers comprise ceramicmaterial, consisting of aluminum oxide, mullite, SiBCN, SiCN or SiC. 13.The turbine disk as claimed in claim 9, wherein the material fiberscomprise ceramic material, consisting of aluminum oxide, mullite, SiBCN,SiCN or SiC.